Method of making aircraft structures



Get. 2, l945..' M. WATTER 6,0

METHOIS F AKiNG AIRCRAFT STRUCTURES Filed Marqh 8, 19-4].

' INVENTOIQ- Michcl el Waiter Patented Oct. 2, 1945 7 Michael Watter,

Philadelphia, vania Application Mai-ch 8, 1941, Serial Nb. ss'2,3s1

(c1. ail-14am 4 Claims.

The present invention is a continuation-inpart of the invention disclosed in my copending application Ser. No. 285,359, filed July 19, 1939, and relates to aircraft, more particularly to a skin-supporting structure for airplane wings and the like, and to a new and improved method of attaching a skin blanket to the wing structure.

Airplane wings ofthe cantilever stressed. skin typegenerally comprise a series of spaced substantially parallel foreand aft-extending ribs having the contour of the airfoil, a skin extending about the ribchords, and transverse shear webs and truss structure for spacing and supporting the ribs. The skin employed for wings of the foregoing character usually is constructed of, sheets of relatively thin, durable metal, such as, for example, stainless steel.

Considerable difliculty has been encountered in the past in providing the metal sheets with a smooth, even surface. In cases where the skin is attached by spotlwelding, the heat produced during the welding operation upsets the metal,

and the subsequent cooling of the thin metal creates a contraction stress around each weld which causes the skin to wrinkle or buckle along the lineof welds. This condition'also occurs when the attachment is made by means of flush rivets. In this case, dimpling of the skin sheets is necessitated, and this likewise results in the METHOD OF MAKING AIRCRAF STRUCTURES a M Philadelphia, Pa., assignor to Edward G. Budd Manufacturing Company, Pa., a icorporati on of; rem s i terial to the framing of an a rcraftiwing o other device by meansof which wrinkles andbulges are eliminated or: minimized, Land-also by a skin blanket comprising thin metal skin sheets and a plurality)ofl relatively -light supporting strips or former secur d to:theinner-surfacesoi the sheets whichnotpnlyincrease the stiiiness of the sheets, and minimize-the deflections tof g the, sheets under load, but alsowhich are attaohable to the wing structure in suchmanner as -t9 mini: mize the creation of. lthe. heretoforementioned bucklingv u ev nne .1lllia r n qaiurbhe aims to provide, a; plurality of transverselyex tending supports for the formers whichg are adapted to be positioned between adjaeentiqribs and attached thereto in such ymanner;t-thatwthem creation of contraction stresses around the dimples. Because of the necessary mechanical work, the skin sheets, like in the case of spot welding, when secured, have abuckled, uneven, wavy appearance.

. The resulting skins are objectionable because the small bulges and wrinkles increase the resistance to airflow. Moreover, on close inspection, the skins give the appearance of poor workmanship. Heavier sheets than otherwise necessary have been employed in order that the stiffness of .the sheet itself might tend to reduce the unevenness. Also, thin skin sheets backed by corrugated"metal sheets have been used in order to produce the required stifiness, but the frequently spaced spot welds necessary to secure the skin sheets and corrugated backing together increases the internal stresses and the unevenness produced by the engagement of the individual corrugations with the skin sheets, toether with the combined Weight of the skin and backing, is disadvantageous.

The present invention aims to overcome the foregoing difficulties and objection by providing a new and improved method of attaching a thin skin sheet of stainless steel or other suitable maincrease the weight: of 1 the wing structure assist in tensioning'the skin sheet. a;

One of vthe'objects ofi the Present invention is to provide a'new1 andimproved gmethod .OfEfiS- sembling. a skin blanketggto a-win structure whereingby reason'thereof, objectionable bucks ling; wrinkling and .thewliketgis minimizedwn, at-4.

Another object; Of? the. present-invention; 5 is -;to, provide a skin-supporting structure for gmini mizing wrinkling or bucklin aiof theg skin sheets and which is adapted to imparta smo0th,;even-; external rappearance t'o-x the skin sheetsfi -m am Another object of? the iinvention -is to i provide a skin-supportingstructure which is; simple and economical in constructioniandi which facilitates assembly of the wing vstructureiand attachment of skin' sheets of highrftensile stren th stainless steel, or "other high strength '-:material, and thy,- means ofwhich spot welding maybe-employed: asthe securing means;-.; 1.

A further bbjectrof-rthe invention is .to providea skin-supporting structure which greatly stilifensthe skin sheets :and' yetsz'is yrelativelyq-light in weight and consequentlyf: does not} substantially- Other and further-Tobi ectsofithdnventio be obvious upon an understanding of the'illus trated "embodiment. about: toiibe described; "013N111 be indicatedin'therappnded=c1aims,gandNarious advantages inot referred-tow;herein will occur to one skilledfiin theart upon inventionin'practice: r1; A preferred embodiment of:the 'invention has been chosen for puiposesgof; illustration; andde scription, and is shown in the accompanying; drawings; forming a .par f then speciiieaticn, wherein Fig. '1' is a fragmentarysperspective viewof an airplane wing of thecantilever type to which he; present invention may he applied;=

employment ,of the;

in solid lines, and in straightened con-ditionin dottedlines, showing one o fithestifl eningwform ers secured thereto; and v v Fig. 6 is a similar view showingz rr solid the skin sheet as applied to straight stiffening in the drawing to comprise a U-shaped bracket 24 having its base spot welded to the flange l8 of chord I! with its legs 26 firmly engaging the sidewall of the chord, as shown at 21 in Fig.2. 7

A second U-shaped bracket28 is disposed within the bracketlflias shOWIi in Fig, 3, 1with its legs 29 extending at right angles to the legs, 26 of ;.;bracket 24 in spaced relation and with its base elements and, in dotted lines, the same after bending to curved shape.

Referring to the accompanying drawing. in

which like numerals refer to like parts throughout the several views, the wing W, as shown "in Fig. 1, comprises a leading or forward section If] which almost entirely carries the loadcausedjby air pressure and vacuum, and a trailing'orr'eab' ward section I l', which in efiect is largely a means for streamlining the leadingsection.

The leading section II] shown, for the purpose of illustration, as comprised of foreand aft extending primary ribs l2, longitudinally extend ing spars 13 of suitable design interconnecting the ribs 12 and suitably reinforced "top and bottom .skin blankets M which terminate approximately at the rearward spar l3,--a indicated at IS in;

Fig. 1.

The present invention case is illustrated imconnection with'the trailingsection' of the wing. However, it is to be understood that it" is not to be considered as limited to this particular section of an aircraft wing, nor, for that matter, to'any particular sectionofan air-craft wing; because it is equally as adaptable to other parts of aircraft and to other devices having thin skin coverings and wherein similar problems are encountered.

The trailing section II in the illustration shown the drawing embodies a plurality" of: spaced trailing ribs t6,-which, depending uponthe particular design ofthe'leading section I0,

may form anintegralpart or the p'rimary ribs l2,

ably secured totherearwardspar l3.

The trailing ribs 16, as here shown. for the purpose of illustration, maycomprisei upp r and be secured tothe trailing ends' thereof, or: be suit-- lower chord elements I T, each channel-shaped in' cross-section and having marginal, laterally ex-. tending flanges 18; The upperand lower chords are interconnected and held'in-spaced relationby angul'arly extending braces or trusses [9. The in-,

vention is not; confined to anyparti'cularconstruction of trailing rib, it only being essential that such ribs have the desired-strength and rigidity; 4

Referring to Figs". 2 and 3 and as 'shownin'Fig,

1, a'plurality of skin blanket supportingele'mentss 26 extend spanwise between each pair of trailing ribs l6. Each element 20 is preferablychannelshaped in cross-section, it having a base2l, andsubstantially parallel legs 22, each of. which terminates in-a marginal laterally extending flange In the completely-assembled structure, the sup porting elements 20 are rigidly secured at their. ends to the adjacent trailing ribs t6. Variousatteaching means" may "be "employed. One: means which has been foundto be satisfactory is shown.

'30 spot welded to the side Wall of the chord I1 The end ofthe supporting element 20 is fitted between the legs 26 of bracket 24 and with the tl'iat eaeh Ieg ZZrof; the supporting element 20 is closely confined-between legs 26 and 29 of the brackets 24, and 28, respectively. These legs,

" y, 22, E l-and 28, at each side of the longitudinalvertical plane of the supporting element 20 are securely welded together, thus providing a reinforced rigid end structure for the supportinge1ement20. g H e The present invention contemplates that,prior to the assembly'of the skin blanket 3| for the trailingsection l I, only one end of'each supporting'element 20 will be secured to the attaching brackets 24 and 28 in'the manner just described. The attaching of theother end to'its brackets 24 and 28, or, in some instances, theattaching of both ends, is leftuntil after the performance of another assembly operationabout to be described. In other applications of the invention, both ends of the elements 20 are secured to their respective brackets" prior to the assembly of the skin blanket 32."

The fskin blanket 3| comprises a skin sheet 32 of the desired metal and a'plurality of spaced skin-stifieningelements 0r "formers 33 extending chordwise between adjacent trailing ribs H5. The formers 33, Whichpreferablyare welded to the skin sheets, as indicated at 34, may be in the form" of relatively light Z-shaped members conforming to the desired airfoil contour and are of suitable stiffness to prevent deflection of the skin sheet 32; The Z shaped formers 33 are provided with parallel oppositely extending flanges 35 and 36, flange 35 consi'itutirigPthe skin-attaching flange, and flange '36constituting an abutment flange for engagement with the supporting element 20,- as shown in Fig." 2. Other structural shapes; however, for the stifiening' elements may be'employed.

:Prior'to'attaching'theskin'sheet 32 to the stiffening elements 33, the stiffening elements, in

one-applicationiof the present invention, are bent to :concavo-convex shape so that, as shown in Fig. 5, the skin-eattaching flanges35 present conca've surfaces and'the'flanges 33 thereof present convex surfaces. v

,The skin 32 is then flexed to have continuous engagementwith the concave surfaces of the stifiening elements 33'and then secured at spaced intervals, preferably 'by spot welding, to the attaching flanges 35 throughout the longitudinal extent thereof; ployed, if desired;

Assuming, first, that the supporting elements 29 have been secured to their respective supporting brackets the assembled skin blanket is disposed upon the .wing structure with the flanges 36 of the stiffening elements 33 engaging the supporting elements 20. Then, by the application of pressureby any suitable means, the stiffening Rivets: however, may be emelements 33 ,are bent fIOIl'L their concave-convex form to'the aerofoil contour and secured. at their I 35 which increases the ends to the wing structure inany suitable manner; the skinalso being' secured 'as desiredtd the ribs and to other structural parts of thwing framing. It is to be understood, of cour'se, that the supporting elements are of such strength as to withstand, without appreciable aerorma tion, the pressures exerted by'the application of the bending pressure to the stiffening ele' t -33; ,2 '1.

Due to the bending of the' stifieni'ng elements 33"from their concave-convex" rsrmm is obvious that I the flanges 35 are "subjected to l tension stresses. Thiscauses air elongationofthe flanges distance" between each pair of adjacent a regions of 'se'curenient; the skin 32 between such regions stretching and being placed under tension. The tensioning of the skin in this manner between the regions of securement tends to smooth out the wrinkling or bulges which occurred during the welding operation in the case of spot welding, or the dimpling operation in the case where flush rivets are used.

If desired, the skin blanket 3!, prior to the bending of the elements 33 from their concavoconvex shape, first, may be secured in place'along one edge, such as, for example, along edge I5, as

viewed in Fig. 1.

In another application of the invention, one or both ends of the supporting elements 20 may be left unsecured and, while backing up the skin blanket 3| in any suitable manner and holding the ends of the stiffening elements 33 against movement laterally of the skin, the stiffening elements 33 may be bent from their concavo-convex shape to the desired aerofoil contour by exerting pressure through the medium of the supporting elements 20, after which the elements 20 may be secured to their respective supporting brackets and the securing of the skin 32 to the other desired framing parts completed.

In either case, the flanges 36 of the stifiening elements 33 may, if desired, be secured to the supporting elements 2|], by welding or any other suitable method.

In another application of the invention, such as, for example (Fig. 6), when the stifienin elements 33 are to have a rounded or curved contour, as when employed as stiffeners for the nose or wing tip portion of the wing, or for a fuselage, the skin sheet 32 and elements 33 may be secured together in the flat and, subsequently, bent to concavo-convex, contour such as to tension the skin-attaching flanges 35, and, consequently, the skin portions disposed between the regions of securement in the manner previously described.

It is to be clearly understood that the tensioning of the skin between regions of securement to the stiffening member may be performed either When the engaging surface of the stiifening element is flat or of concave contour, the controlling factor, of course, being the particular contour the skin blanket is to have in the completed structure.

From the foregoing description, it will be seen that the present invention provides an improved skin-supporting structure for aircraft constructions, and a new and improved method of attaching a skin sheet or blanket to metal framing. The structure has a high tensile strength and is adapted to resist longitudinal an transverse bending stresses, but yet is relatively light in weight. I A minimum number of parts are utilized which enables the structure to be readily assembled in an economical manner, and the parts of the structure are arranged to facilitate deredstiffiwith aminimum of rigidifying-structure, as well as'a minimum number of spotwelds,

and the entirestructure canbe fabricated by'spot wading; the skin sheet and former element's being assembled to the frame as a subassembly,

While the present invention has been shown and described in connection with the skin blanket for the upper side of the trailing section of the wing, it is to be understood that the same applies as 'well to the skin blanket for the lower side of this section, and to other structures in which a skin sheet is applicable.

In the appended claims, the terms distending and deformed, where used, are to be construed as meaning any action upon the elements secured to the skin sheet, whether it be by bending or the application of any other force, which tends to elongate that portion of the metal of the elements engaged with the skin sheet.

As various changes may be made in the form, construction and arrangement of the parts, and in the steps in the method herein described without departing from the spirit and scope of the invention as defined in the appended claims, and

without sacrificing any of its advantages, it is to,

be understood that all matter herein is to be interpreted as illustrative and not in a limiting sense.

What is claimed is:

1. In the art of making aircraft and the like structures, the method of attaching a thin con- .tinuous metallic sheet skin to a metallic frame element which comprises disposing the skin and element in substantially continuous engagement, spot welding the skin and element together at spaced points defining several intervals longitudinally of the element, then bending the element in a direction perpendicular to the surface of the skin and in a direction such as to distend the portion of the element adjacent the skin whereby to tension the skin portions disposedbetween the regions of welding, and retaining the element in bent condition.

2. In the art of making aircraft and the like structures, the method of producing a reinforced metallic skinblanket having a continuous metallic sheet skin and a metallic stiffening element which consists in bowing the stiflening element to present a concave surface and a convex surface, disposing the skin in substantially continuous engagement with the concave surface, rigidly securing the skin to the stiffening element at spaced points defining several intervals, and thereafter bending the stiffening element from its bowed condition to the final form it is to assume whereby to tension the portions of the skin disposed between the regions of securement, and then fixing said stiffening element in said final form.

3. In the art of making aircraft and the like structure having spaced ribs and supporting ele- 4mm: the-art oi ,makingeircrafitand the like structures; the method-oi producing eat-structure hsvingzga frame-elementend a thin, continuous metal skin sheet secured thereto and substantial- 1y covering said-frame, which includes the steps oi-seeuningthe skin sheet in taut condition to erting pressure a. direction perpendicular to-the I surface of the skin and from the skin side and toward thesupporting elements to bend the stif feni-ng elements and distend the metal thereof adjacent the skin and thereby tension the skin portions lying between the spot welds, andthen securing the simporting. and stiffening elements in position.

one sidezoie frame element at several spaced thereon throughout its length, and tensioning the skin sheet between its points of seeurement ta theirame'element by bending the irameelement between the points of securement bya.;.iorce intacdirection normal to and toward the skin sheet to the-final form it is to assume,

and thenflflxing sazid tframei element and skin I sheetinzsaid final town 7 MICHAEL. WATTER. 

